Panel form for concrete construction



Dec. 13, 1966 Filed June 27, 1963 E. P. BERGHAMMER PANEL FORM FOR CONCRETE CONSTRUCTION :5 Sheets-Sheet 53 fiFIBERGLASS I 1 RESIN INVENTOR.

EDWARD R BERGHAMMER BY LLCULM Miorneys Dec. 13, 1966 E. P. BERGHAMMER 3,291,43fi

PANEL FORM FOR CONCRETE CONSTRUCTION Filed June 27, 1963 5 Sheets-Sheet 3 United States Patent Ofitice 3,291,436 PANEL FQRM FOR CONCRETE QONSTRUCTION Edward P. Berghammer, 9548 Beverly Place, Wauwatosa, Wis. Filed June 27, 1963, Ser. No. 290,993 7 Claims. "(CL 249-46) This invention relates generally to concrete form construction and more particularly to an improved unitary panel for utilization in concrete forming assemblies.

The subject application is a continuation-impart of United States patent application Serial No. 821,217, filed June 18, 1959, entitled Panel Form for Concrete Construction, now abandoned.

It has been the practice, in the pouring of concrete, to use panel forms made of Wood or metal. Many disadvantages are present in the use of either material. For instance, if wood panels are used to constrain concrete in forming, the life expectancy of the panel is quite limited. As the wet concrete hardens or sets within a composite structure of wooden panels, the concrete tends to adhere to the face of the panels and make stripping of the panels from the set concrete diflicult. Because of the undesirable adherence between a wooden panel and the concrete, portions of the wood facing occasionally become embedded in the concrete. Also, if wood panels are used, th irregularities in the face of the panel are imprinted in the surface of the hardened concrete. After each use the panel face must be cleaned, as by wire brushing. Also, the surface of the poured concrete must be'worked so that a relatively smooth surface may be obtained. In the event that the face of the panel is damaged to any great extent during use, the panel must be replaced; if repairable, it is still relatively costly in time and materials. In order to provide the requisite strength, the frame of the wood panels must be fabricated of relatively large structural members resulting in a heavy assembly.

On the other hand, if metal panels are employed, it is necessary to not only clean the panel face after each use, as in the case of wood panels, but also to coat the face of the panel in order to preserve the panel surface and to aid in stripping the panels from the concrete after setting. In addition, metal forms are heavy, entailing greater effort in both rigging the same for use and in storing the same between uses.

A general object of the invention is to provide a new and improved panel construction especially adapted for concrete forming.

A further object of the invention is to provide a new panel construction comprising a unitary rigid member having a high density face which is impervious to water and will not adhere to concrete.

A still further object is to provide a plastic faced panel for use in concrete forming which may be readily stripped from the concrete after the same has set or hardened and which does not thereafter require laborious and costly cleaning operations which ultimately results in deterioration of the panel.

Another object is to provide an integral panel of the same general dimensions as a conventional wood panel but lighter in weight and vastly stronger in resisting pressures to which it is subjected in concrete forming use.

Still another object is to provide an improved panel which is particularly simple to manufacture and yet extremely rigid and rugged.

These and other objects will appear from the following description when read in conjunction with the drawing in which:

FIG. 1 is a plan view of the panel taken from the rear side of the panel.

FIG. 2 is a side elevational view;

3,291,435 Patented Dec. 13, 1966 FIG. 3 is an enlarged view taken on line 3-3 of FIG. 1;

FIG. 4 is an exploded enlarged view taken on the same line as FIG. 3.

FIG. 5 is a perspective view of a form for pouring a concrete column, the form being assembled of panels that incorporate the features of the present invention;

151G. 6 is a plan view of the form depicted in FIG. 5; an

FIG. 7 is a perspective view of a form for preparing a concrete column, the form being assembled of conventional panels, portions of the clamping devices being omitted to better illustrate the panel structure.

With reference to the drawing, and particularly to FIGS. 1 and 2 thereof, an integralmolded panel form 11 is provided with a face 12 and a rearwardly disposed flange 13 which extends around the entire perimeter of the face. A plurality of reinforcing cross ribs 14 are juxtapositioned between the longitudinal flange rails 13. The face 12 presents a smooth monolithic surface 15 of a suitable polyester resin-which is particularly resistant to abrasion and capable of withstanding high impact forces without damage.

Basically, each panel form'11 is comprised of a plurality of filler or core members 16 which may be of any suitable material. The face member 12 as well as the flange and cross-rib members 13 and 14 are dimensionally cut of such material. Such filler or core members, when properly oriented provide the configuration for the panel form. Thus, when such members are embedded within a homogeneous mass of Fiberglas and polyester resin, a unitary structure results. The specific interrelation between the material and the Fiberglas-resin mass is shown in FIG. 3.

The method employed in the manufacture of a panel form 11 is depicted in FIG. 4. Initially, the cavity of a suitable mold or die 19 is sprayed or coated with resin; a Fiberglas material of uniform weight and thickness is then applied onto the resin coated die surface. Thereafter, the remaining face of the material is sprayed or coated with resin. The individual filler members 16 are then positioned Within the mold with a portion of their faces engaging the plastic resin. The remaining exposed surfaces of the filler members are successively covered with a layer of resin, a layer of Fiberglas and a final layer of resin to weld all of the components into an integral panel unit.

The resin employed is preferably of a type which is catalytically set, so that when the assembly is completed and the parts pressed together to eliminate air pockets and to shape the same to prescribed dimensions, the resin is set with the Fiberglas and the core integrally embedded therein, as shown in FIG. 3.

The several filler members 16 are not assembled into a framework before placement in the die cavity. They are individually placed in the die and are only united by the enveloping plastic to form a unitary structure and establish the configuration of the panel. The filter members 16 may be formed of a variety of materials as their sole purpose is to establish the configuration and impart rigidity to the plastic. The tensile and compressive strengths of the panel are obtained from the plastic itself. For example, the filler or core material might conceivably be a suitable honeycomb material of treated Kraft paper of a prescribed thickness and having a predetermined load capacity required to impart rigidity to the completed panel; as a result, the panel is of substantially lighter weight than the conventional wood panel of corresponding overall size. The panel is able to withstand far greater loads by reason of the characteristics of the plastic material. Furthermore, the dimensional sizes of the filler members 16 can be considerably reduced from the dimensional sizes of the members in the framework of a conventional panel member as presently known to the construction trade.

As an alternative, a rigid cellular core may be provided internally of the panel by employing a foaming agent in the assembly process. For this purpose, the resin and Fiberglas layers forming the outer or front face of the panel may be assembled in a female die member and those forming the inner or rear face of the panel may be assembled on a male die. Then a liquid mixture which will foam to produce a cellular core structure is poured onto the assembly in the female die and the two dies are brought together to complete the assembly. The cellular core is thereby formed by expansion of the foaming agent and simultaneously with the setting of the plastic casing material. Because the expansion occurs under pressure the foaming agent, which should be selected for flow and moldability, finds its way into all openings no matter how small.

The panel illustrated is of standard size and shape for general use in the construction of concrete walls, floors, and the like; standard panels of 2' x 8' and also 2 x 4' sizes are regarded as most suitable. In view of the number of panels required, the present invention will permit large savings in cost by virtue of automatic machine manufacture. Special shaped or sized panels may be readily made by manual processes, or machine manufacture if quantity permits.

For example, modern design frequently provides for curved concrete structures which would require correspondingly curved forms in which to pour the concrete. Curved panels can be readily constructed in accordance with the teachings of the present invention to create the forms for forming the curved concrete structures. In addition, it is architecturally desirable to form aesthetic designs in concrete walls .to improve their appearance. Such designs may be very readily provided in the panels of the present invention by forming the desired design in the mold and, consequently, the panel. The resin and Fiberglas will readily conform to such design in the mold even though the design is extremelycomplex.

In order to illustrate the greater strength available from panels of the inventive type, a columnar form made up of an assembly of panels manufactured according to the teachings of the subject invention is shown in FIG. 5; the form is secured to a concrete footing 23. The assembly comprises four panels 25 uprightly disposed and resting on edge in a manner to form a square cavity with each of the panels defining one side of the cavity. The four panels are retained in the assembled position by four clamps, 26, of a well known type especially designed for retaining panels in a columnar form. The clamps are each comprised of four bars 30 with each bar extending exteriorly across a panel in a manner that the clamp surrounds the assembled fonm. The ends of the bars 30 are provided with openings for receiving tapered pins 31 to adjustably secure the four bars 30 together, as shown in FIGS. 5 and 6.

Since the panels 25 are of substantial thickness and are disposed in juxtaposition at right angles to adjacent panels, a void exists at each corner of the (form. In order to provide suitable gripping area for the clamps 26, filler members 32 are inserted into the corner voids adjacent the clamps. The filler members 32, of course, are square and of a dimension corresponding to the thickness of the panels 25. Each of the panels 25 includes a plurality of ribs 33 which serve to impart rigidity to the panel.

FIG. 7 illustrates an assembly of panels 35 disposed to create a form for producing a concrete column identical in shape and size to the column produced by the form illustrated in FIG. 5. However, the four panels 35 are manufactured in accordance with conventional wood construction in which a plywood .face board 36 is nailed or otherwise secured to a wooden frame fabricated of 2" x 4" lateral ribs 37 and peripheral members 38. The four panels 35 are held together in the desired form con- 4 figuration by a plurality of clamps 26 identical to the clamps 26 illustrated in FIG. 5. The column formed by the panels 35 is similarly secured to the footing 23. The voids at the juncture of the four panels 35 are likewise occupied by filler members 32 to provide a continuous bearing surface for clamps 26.

The two columnar form assemblies illustrated in FIGS. 5 and 7 are identical in size and height. However, since the panels 25 of the present invention are of vastly greater strength than the conventional wood panels 35, the entire form assembly (FIG. 5) can be poured full of concrete to the full height of the column in a single pour without distorting the form. On the other hand, the form assembly depicted in FIG. 7 requires the filling of the form with concrete in three successive steps with each pour filling one third of the form; a minimum of twenty minutes must elapse between each pour.

The form assembly shown in FIG. 5 can be filled with a single pour in comparison to the three separate pours for the form assembly shown in FIG. 7 despite the fact that the panels 25 are each provided with only three intermediate ribs 33 while the wood panels 35 require at least four intermediate ribs 37 and possibly more. In addition, it will be noted that the [form assembly in FIG. 5 will accept a single pour of concrete while being secured by four clamps 26 whereas the form assembly of FIG. 7 requires seven clamps 26 adequately spaced along the height of the form to preclude distortion of the form assembly. The clamps 26 must be more closely spaced adjacent the bottom of the form to withstand the increased load in this area and to avoid rupture of the form. The additional clamps are required with the wood panels 35 despite the fact that the concrete must be poured in three separate stages.

Although the illustrations depicted in FIGS. 5, 6 and 7 relate to a form assembly for pouring a concrete column, it should be understood that the improved panels incorporating the present invention may likewise be used in all forming operations. For example, a plurality of the panels may be secured together edgewise in spaced apart sections to provide forms for the construction of foundations, walls, floors and the like. The conventional spacing ties and securing devices can be used in a well known manner to lock the panels together in any desired form. After the concrete or other material has set, the panels can be readily removed and reused over an extended period of time without further servicing.

It is therefore apparent that the plastic panels of the present invention provide many advantages over the conventional wooden panels heretofore employed by the construction industry. For example, because of the smooth surface provided by the plastic face of the present panel, the panel may be readily stripped olf the set concrete without damage to either concrete or panel. The difficult cleaning of the panel face is eliminated because concrete does not adhere to the plastic face of the panel; likewise, the treating of the panel face after each use is completely eliminated. Panels constructed in accordance with the teachings of the present invention may be exposed to the elements indefinitely without deterioration and will withstand far greater abuse without damage. As previously described, despite the fact that the plastic panels of the present invention are of substantially lesser weight than the plywood or metal panels, the improved panels contain such appreciably greater strength as to enable the form assemblies to be rapidly filled with concrete in a rnini- I The embodiments of the invention in which an exclusive property -or privilege is claimed are defined as follows:

Iclaim:

1. In a mold for receiving poured material which will solidify in the mold; sheet material; filler members disposed on said sheet material in the shape of a frame with the frame backing said sheet material; and a plastic coating enveloping said sheet material and said filler members to unite the assembly in a unitary structure with the plastic coating presenting a smooth impervious surface for engagement with the concrete poured into the form.

2. A unit panel section disposed for selective assembly into a concrete form and comprising a plurality of filler members arrayed in a manner to provide a panel frame configuration, a face member in abutment with one side of the panel frame to provide a unit panel configuration, and an integrator envelope molded to unitarily cover the remaining exposed surfaces of said filler members and said face member whereby a panel section of predetermined size and shape having superior strength characteristics is provided for use in plastic concrete forming.

3. A unit panel assembly comp-rising a plurality of filler members disjointly arranged in a predetermined panel frame array, a face member disjointly disposed in abutment with said filler members, and a resin and Fiberglas envelope over the remaining exposed surface of said filler members and said face member whereby the entire assembly is formed into an integrated whole.

4. In a panel for assembling into concrete forms for receiving poured concrete; a sheet material having a front face and a back face; a plurality of filler members disposed on the back face of said sheet in the shape of a frame extending outwardly from the back face of said sheet; and a coating of resin impregnated Fiberglas enveloping the exposed surfaces of said sheet and said members to form a unitary structure with said resin impregnated Fiberglas serving to create the necessary strength in the panel while presenting a smooth impervious surface for engagement with the concrete within the form.

5. In a concrete form for receiving poured concrete; a plurality of panels supported in position to produce the desired form, each of said panels being fabricated of a sheet of material; a plurality of filler members disposed on said sheet in the shape of a frame; and a single integrated coating of plastic enveloping said sheet and said members to form a unitary structure with said plastic presenting a smooth impervious surface with the concrete within the form.

6. in a concrete form for receiving poured concrete; a plurality of panels supported in position to produce the desired form, each of said panels being fabricated of a sheet of material having a front face and a back face; a plurality of filler members extending outwardly from the back face of said sheet and being assembled into the shape of a frame; and an integrated coating of plastic enveloping said sheet and said filler members to form a unitary structure with said plastic presenting a smooth impervious surface on the front face of said sheet for engagement with the concrete within the form whereby a smooth finished surface on the hardened concrete results after the form is removed.

7. In a mold assembly adapted for use in poured concrete forming; each panel of the assembly comprising a sheet material; filler members assembled to provide a frame disposed to engage one face of said sheet material; said sheet material and filler members serving to define a predetermined configuration for each panel; a plastic envelope unitari ly molded over the sheet material and filler members, said molded envelope being comprised of Fiberglas-reinforced resin having strength characteristics capable of withstanding the progressive accumulation of forces resulting as liquid concrete of high density is rapidly poured into the mold assembly.

References Cited by the Examiner UNITED STATES PATENTS 1,463,841 8/1933 Richman 264-219 2,625,710 1/1953 Lockwood 1834 2,640,249 6/1953 Symons 25131 2,707,801 5/1955 Gard 25-1'22 X 2,753,603 7/1956 Strawther 2053 X 2,809,415 10/1957 COuelle 264-219 2,832,995 5/1958 McCaW 18-34 2,859,503 11/1958 Hennig 25131 2,896,271 7/1959 Kloote et al. 204 2,907,070 10/1959 Van Hartesveldt 25-130 X I. SPENCER OVERHOLSER, Primary Examiner.

ALEXANDER H. BRODMERKEL, MICHAEL V.

BRINDISI, WILLIAM J. STEPHENSON, J. HOW- ARD FLINT, JR., Examiners.

J. R. DUNCAN, G. A. KAP, Assistant Examiners. 

3. A UNIT PANEL ASSEMBLY COMPRISING A PLURALITY OF FILLER MEMBERS DISJOINTLY ARRANGED IN A PREDETERMINED PANEL FRAME ARRAY, A FACE MEMBER DISJOINTLY DISPOSED IN ABUTMENT WITH SAID FILLER MEMBERS, AND A RESIN AND FIBERGLASS ENVELOPE OVER THE REMAINING EXPOSED SURFACE OF SAID FILLER MEMBERS AND SAID FACE MEMBER WHEREBY THE ENTIRE ASSEMBLY IS FORMED INTO AN INTEGRATED WHOLE. 